Modular ASRS Rack and Robot Elevator for Flexible Warehouse Layouts
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Solution Overview
Problem
Existing automated storage and retrieval systems lack flexibility in design, particularly in adapting to various installation environments and improving efficiency in item storage and picking processes.
Innovation Solution
An automated storage and retrieval system featuring a rack with modular support column modules that allow for flexible configuration, a transportation robot capable of moving along the rack's surface, and a transportation elevator that can move between floors, utilizing a sprocket and roller chain mechanism for vertical transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed structure automated storage and retrieval system is used, then the system structure is simple, but the system lacks flexibility in adapting to various installation environments
Solution Approach 1:
The rack is divided into multiple modular support column modules that can be independently assembled and configured. Each module contains standardized components that can be combined in different arrangements to create flexible rack structures adapted to various installation environments while maintaining structural integrity
Solution Approach 2:
The support column modules are designed with universal coupling mechanisms (insertion plugs and accommodation plugs) that allow the same modular components to serve multiple functions and be assembled in various configurations, enabling the system to adapt to different spatial requirements without requiring entirely different structural designs
2Productivity
If manual item picking is used, then the system structure is simple, but the item picking work efficiency is low
Solution Approach 1:
The transportation robot autonomously navigates the rack structure, locates bins, and transports them to picking stations without human intervention. The system self-manages the transportation tasks, freeing operators to focus solely on efficient item picking and order fulfillment
Solution Approach 2:
The transportation robot acts as an intermediary between the storage bins and the picking stations, handling the transportation task while allowing human operators to specialize in the picking and sorting operations, thereby optimizing overall workflow efficiency
3Adaptability or versatility
If traditional conveyer systems are used for tray transport, then the system structure is simple, but the flexibility in designing automated storage and retrieval forms is limited
Solution Approach 1:
The system replaces fixed conveyor paths with a dynamic robotic transportation platform that can adapt its movement routes and stopping positions based on real-time order requirements and rack configuration, enabling flexible design while maintaining operational efficiency through programmable control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible design and enhances efficiency in item storage and retrieval processes, optimizing storage and delivery operations.
Implementation Method 1
The driven part of the transportation elevator is a sprocket, and the engagement member is a roller chain
Data Source
AI summary
There is provided an automated storage and retrieval system including: a rack storing a plurality of bins for containing items; a transportation robot transporting the bin in the rack; and a transportation elevator which moves in the rack and can transport the transportation robot. The rack includes a plurality of floors each of which stores each of the plurality of bins, and allows the transportation robot to run along a surface thereof, and the rack includes a plurality of support column modules forming a passage of the transportation elevator. Each of the support column modules extends between at least mutually neighboring floors, and one support column module is configured to be able to be coupled to the another support column module.